Turbo Housing Replacement! HELP!!!

[Dan007]

Not sure which forum to post this in -- but here's the problem:

I am trying to replace my 12 cm turbo housing with a 16 cm one that I purchased from Auto Wurks. The new one and the old one look very different. The old one (which I am having trouble removing) seems to have mechanical "stuff" hooked to it that the new one doesn't. My Chilton manual shows a picute of the new one so I don't know how to proceed. Any help would be appreciated Thanks in advance.

This is on a 95 Dodge 3/4 ton 4x4 -- I am writing this for my husband who is out hammering away on the truck

 

[moparguy]

First of all, I'm no expert, but it can be done. I've done this once, finished up last night. The original housing has a waste gate, that controlled the amount of boost, that's the extra stuff you're seeing. Keeps boost in check, good for the factorys goals, not necessarily ours. The replacement 16cm2 housing is non-wastgated. After removing the turbo, it's necessary to move the exhaust toward the turbo position about 1 1/2". I accomplished this, by attaching a come-a-long to the exhaust system at the back side of the muffler, and hooked the other end to the front of the truck and put a pretty good load on the cable, then heated up the big exhaust support rod that's attached on the right side of the transmission with a torch till it was red, hit the rod a few times with a hammer and moved the exhaust the necessary amount. I made a coupla of reference marks on the frame to judge movement since I was working by myself.



To seperate the housing halves, I used lots of Liquid Wrench, after removing two of the four stainless bolts that clamp the half moon retaining pieces and loosing the other two (it was necessary to do a lot of grinding to a 13mm boxed end wrench to break the two tough to reach ones loose), I then used two big screw drivers as levers to apply pressure to the cold side housing, (thanks Rammin-On). Had to tap the handles of the screwdrivers with the hammer (fairly hard) to start the seperation process. Be careful not to do to much on any one side since it's possible to lock up and bend or otherwise damage the turbo shaft, be careful. Alternate back and forth between the two sides. I used a brass hammer to help at this point.



TST has instructions on there site that might be helpful.



One last thing, it's necessary to get a 1/8" brass plug to plug the boost elbow opening in the cold side of the turbo (has a line that goes to the wastgate on the stock setup). This is a tapered hole, so a bolt might not work as well as the plug.



Good luck,



Ronnie

 

[MikeR]

Just like moparguy said... the new 16 is shorter than the 12 because there is no wastegate. If you don't want or have the means to bend the exhaust system forward to reach the new housing,then you can purchase a 1-1/4 spacer from Diesel Injection of Pittsburg.



-Mike